Fireplace insert

ABSTRACT

A fireplace insert comprising: a gas burner, a fuel/air control valve coupled to the gas burner, a blower coupled to the gas burner, and a controller coupled to the fuel/air control valve and the blower; wherein the controller controls at least one operational parameter of the fuel/air control valve and the blower to produce a flame pattern generated by the gas burner. A method of manufacturing is also provided.

TECHNICAL FIELD

This application is directed, in general, to a fireplace and, more specifically, to a modulating flame gas fireplace.

BACKGROUND

Even with the advent of central heat, many homes and business still use fireplaces. In some instances, they are used to produce additional heat for a given space, however, in other applications, their presence is purely aesthetic. Many of the advances in fireplace technology have primarily been in the arena of providing fireplace systems that are designed to better transfer the heat generated by the fire. This has particularly been the case with the advent of natural gas fireplaces that are much cleaner and more convenient than conventional wood-burning fireplaces.

SUMMARY

One aspect provides a fireplace insert comprising: a gas burner, a fuel/air control valve coupled to the gas burner, a blower coupled to the gas burner, and a controller coupled to the fuel/air control valve and the blower; wherein the controller controls at least one operational parameter of the fuel/air control valve and the blower to produce a flame pattern generated by the gas burner.

A method of manufacturing a fireplace insert comprising: providing a gas burner, coupling a fuel/air control valve to said gas burner, coupling a blower to said gas burner, and coupling a controller to said fuel/air control valve and said blower wherein said controller controls at least one operational parameter of said fuel/air control valve and said blower to produce a flame pattern generated by said gas burner.

BRIEF DESCRIPTION

Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a partial sectional view of one embodiment of a fireplace insert constructed in accordance with the principles of the present disclosure;

FIG. 2 is a sectional view of the burner and flame pattern of FIG. 1;

FIG. 3 is a partial sectional view of an alternative embodiment of the fireplace insert;

FIG. 4 is a partial sectional view of a second alternative embodiment of the fireplace insert; and

FIG. 5 is a partial sectional view of a third alternative embodiment of the fireplace insert.

DETAILED DESCRIPTION

FIG. 1 illustrates a partial sectional view of one embodiment of a fireplace insert 100 constructed in accordance with the principles of the present disclosure. In this embodiment, the fireplace insert 100 comprises: a gas burner 110, a fuel/air control valve 120, a blower 130, and a controller 140. The gas burner 110 may be of any desired shape; however, gas burners having a particular horizontal geometric cross section 2A-2A, e.g., circular, rectangular, elliptical, inverted cone, etc., have special application in that they readily produce flame cross sections 2A′-2A′ that reflect, or are similar, to that of the burner horizontal geometric cross section, i.e., circular, rectangular, elliptical, inverted cone, etc., respectively. A gas burner 110 with a circular cross section is illustrated in FIG. 2. Also, in one configuration, the gas burner 110 may have a bowl-shaped vertical cross section as can be seen in FIG. 1 and the flame pattern 150 has a similar vertical cross section emanating from the top 111 of the gas burner 110. Some of the geometric cross sections into which the gas burner may be configured are illustrated and discussed below. One who is of ordinary skill in the art will readily conceive of other geometric cross sections applicable within the principles of the present disclosure.

In certain embodiments, the fuel/air control valve 120, the blower 130, and the controller 140 of the fireplace insert 100 may be powered by conventional line voltage of 110-115 VAC. However, in other embodiment, the fuel/air control valve 120, the blower 130, and the controller 140 may be powered by direct current. The blower 130 is pneumatically coupled to the gas burner 110 through a duct 160, such as gas pipes, which has the fuel/air control valve 120 interposed the blower 130 and the gas burner 110. The controller 140 comprises a microprocessor with a programmable memory for controlling at least one operational parameter of the fuel/air control valve 120 and the blower 130. In one embodiment, the controller 140 may command a set program over a specified period of time and then cyclically repeat the program. In another embodiment, the controller 140 may be set to command a varying function so as to give the appearance of a traditional wood fireplace with varying flame colors and heights. In an alternative embodiment, the controller 140 may be replaceable as a complete unit or a plug-in board, each different unit having a specific program preprogrammed. Alternatively, the controller 140 may be reprogrammed through a USB connection to a personal computer.

The operational parameters of the fuel/air control valve 120 and the blower 130, in certain embodiments, may include the following: fuel (natural gas or propane) velocity, air velocity, fuel/air ratio, and an equivalence ratio. The fuel velocity may be controlled by setting the fuel/air control valve 120 with the controller 140 sensing the line gas pressure and adjusting the fuel/air control valve 120 appropriately. The air velocity may be controlled by the rotation speed of the blower 130 and the setting of the fuel/air control valve 120 by the controller 140. The fuel/air ratio may be controlled by the controller 140 when it sets the fuel/air control valve 120 for the proper mix to obtain a desired fuel/air ratio. The equivalence ratio φ is defined as: (F/A ratio)_(actual) divided by (F/A ratio)_(stoichiometric). One who is of skill in the art is familiar with the meaning of a stoichiometric fuel/air ratio. The equivalence ratio may be determined by the controller 140 for appropriate adjustment as necessary for a desired flame pattern or color.

The operational parameters of the fuel/air control valve 120 and the blower 130 can affect the flame pattern. For example, if a constant fuel/air ratio is maintained, but the volume of fuel and air is increased, the length of the flame will increase. That is, height h of the flame pattern is a direct function of the volume of fuel and air delivered to the burner 110 by the blower 130. If the constant fuel/air ratio is maintained, but the volume of fuel and air is decreased, the length of the flame will also decrease. If the flow volume of fuel and air is increased by increasing fuel while holding the air constant, then the flame will tend to be more yellow in color. If the opposite is commanded, i.e., the flow volume of fuel and air is increased by increasing air while holding the fuel volume constant, then the flame will tend to be more toward blue in color. These various operational parameters of the fuel/air control valve 120 and the blower 130 are controlled by the controller 140 adjusting the fuel/air mixture with the fuel/air control valve 120 and the flow volume by increasing or decreasing the rotational speed of the blower 130. By adjusting one or more of the operational parameters, a very artistic flame having different heights, colors, or both over a programmed period of time may be easily achieved. The time may be varied in such a way so to create a constant changing flame or produce repeated patterns over a set period of time, much in the same way as a water fountain might be operated.

FIG. 2 illustrates a sectional view of the burner 110 and flame pattern of FIG. 1. As can be seen, the flame pattern reflects the burner shape.

FIG. 3 illustrates another embodiment of a fireplace insert 300. In this particular embodiment, the fireplace insert 300 comprises: a multiple gas burner 310, a fuel/air control valve 320, a blower 330, and a controller 340. The number of gas burners 310 may vary depending on the desired design. FIG. 3 illustrates one such design that is configured as a dual gas burner. The illustrated dual gas burner 310 has two concentric bowl-shaped burners 311, 312. The fuel/air control valve 320, blower 330, and controller 340 combine to produce two concentric flame patterns 351, 352 from the two concentric bowl-shaped burners 311, 312. In this configuration, the flame patterns of the individual burners 311, 312 will be substantially parallel to each other because the individual burners 311, 312 are fed and controlled by the same fuel/air control valve 320, blower 330, and controller 340. However, one flame pattern h₁, h₂ may be longer or shorter than the other by controlling the fuel/air entrance orifices 313, 314 of each burner 311, 312, respectively.

As with previous embodiments, the operational parameters of the fuel/air control valve 320 and the blower 330 can be varied to affect the flame pattern and be operated and controlled by way of the controller 340 in the manner described above, such that by adjusting one or more of the operational parameters, a very artistic flame having different heights, colors, or both over a programmed period of time may be easily achieved. The time may be varied in such a way so to create a constant changing flame or produce repeated patterns over a set period of time, much in the same way as a water fountain might be operated.

FIG. 4 illustrates a partial sectional view of a second alternative embodiment of a fireplace insert 400. The fireplace insert 400 comprises: first, second, and third gas burners 411, 412, 413, a fuel/air control valve 420, a blower 430, and a controller 440. All three gas burners 411, 412, 413 are fed from the same fuel/air control valve 420, blower 430, and controller 440. In this configuration, the first and second gas burners 411, 412 are inverted cone-shaped. The first and second gas burners 411, 412 produce inverted, truncated cone-shaped flame patterns 415, 416, respectively, that may be varied in color by adjusting the flow velocity for each burner 411, 412. For the first and second burners 411, 412, this is achieved by selection of the size of the aperture 419 in a split disk 414 surrounding a central tube 417 that feeds the third burner 413. The third gas burner 413 may be designed to produce a conventional single flame that is more yellow in color. This color is achieved by controlling the aperture size of a flared end 418 of the central tube 415. Flame heights of the burners 411, 412, 413 and the overall flame patter may be controlled as detailed above with respect to other embodiments.

FIG. 5 illustrates a partial sectional view of a third alternative embodiment of the fireplace insert 500. In this particular embodiment, the fireplace insert 500 comprises: first through fifth gas burners 511-515, first and second fuel/air control valves 521, 522, first and second blowers 531, 532, and first and second controllers 541, 542. Though the design may vary, the illustrated embodiment shows the first and second gas burners 511, 512 configured as two concentric bowl-shaped burners 511, 512. The third, fourth, and fifth gas burners 513, 514, 515 may be conventional single flame burners. The first and second gas burners 511, 512 are served by the first fuel/air control valve 521, the first blower 531, and first controller 541. The third, fourth and fifth gas burners 513, 514, 515 are served by the second fuel/air control valve 522, the second blower 532, and the second controller 542. Each of the first and second controllers 541, 542 may have different programs to enhance contrast between the two types of burners, i.e., the first and second gas burners 511, 512 vs. the third, fourth and fifth gas burners 513, 514, 515. Flame height and color of each set of burners are controlled as detailed above.

Thus, a fireplace insert has been described that controls not only the height of the flame pattern emanating from multiple burners, but also, the shape and color of the flames.

For the purposes of this discussion, use of the terms “providing” and “forming” includes: manufacture, subcontracting, purchase, etc. Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments. 

1. A fireplace insert, comprising: a gas burner; a fuel/air control valve coupled to said gas burner; a blower coupled to said gas burner; and a controller coupled to said fuel/air control valve and said blower wherein said controller controls at least one operational parameter of said fuel/air control valve and said blower to produce a flame pattern generated by said gas burner.
 2. The fireplace insert as recited in claim 1 wherein said gas burner has a geometric cross section.
 3. The fireplace insert as recited in claim 2 wherein said gas burner is configured to provide a flame pattern that has a similar flame cross section to said geometric cross section.
 4. The fireplace insert as recited in claim 1 wherein said at least one operational parameter of said fuel/air control valve and said blower is selected from the group consisting of: a fuel velocity; an air velocity; a fuel/air ratio; and an equivalence ratio.
 5. The fireplace insert as recited in claim 4 wherein said equivalence ratio is defined as (F/A)_(actual) divided by (F/A)_(stoichiometric).
 6. The fireplace insert as recited in claim 1 wherein said fuel/air control valve is coupled to multiple burners.
 7. The fireplace insert as recited in claim 1 wherein said gas burner is a first gas burner and said fireplace insert further comprising second and third gas burners coupled to said fuel/air controller.
 8. The fireplace insert as recited in claim 1 wherein said gas burner, said fuel/air control valve, said blower, and said controller are a first gas burner, a first fuel/air control valve, a first blower, and a first controller, respectively; and wherein said first fuel/air control valve, and said first blower are coupled to said first gas burner and said first controller is coupled to said first fuel/air control valve, and said fireplace insert further comprising: a second gas burner; a second fuel/air control valve coupled to said second gas burner; a second blower coupled to said second gas burner; and a second controller coupled to said second fuel/air control valve wherein said second controller controls at least one operation parameter of said second fuel/air control valve and said second blower to provide a second flame pattern generated by said second gas burner.
 9. The fireplace insert as recited in claim 8 wherein said at least one operational parameter of said second fuel/air control valve and said second blower is selected from the group consisting of: a fuel velocity; an air velocity; a fuel/air ratio; and an equivalence ratio.
 10. The fireplace insert as recited in claim 8 wherein said first and second control valves are coupled to multiple burners.
 11. A method of manufacturing a fireplace insert, comprising: providing a gas burner; coupling a fuel/air control valve to said gas burner; coupling a blower to said gas burner; and coupling a controller to said fuel/air control valve and said blower wherein said controller controls at least one operational parameter of said fuel/air control valve and said blower to produce a flame pattern generated by said gas burner.
 12. The method as recited in claim 11 wherein providing includes providing a gas burner having a geometric cross section.
 13. The method as recited in claim 12 wherein providing includes providing a gas burner that has a similar flame cross section to said geometric cross section.
 14. The method as recited in claim 11 wherein coupling a controller includes coupling a controller wherein said at least one operational parameter of said fuel/air control valve and said blower is selected from the group consisting of: a fuel velocity; an air velocity; a fuel/air ratio; and an equivalence ratio.
 15. The method as recited in claim 14 wherein said equivalence ratio is defined as (F/A)_(actual) divided by (F/A)_(stoichiometric).
 16. The method as recited in claim 11 wherein coupling a fuel/air control valve includes coupling a fuel/air control valve wherein said fuel/air control valve is coupled to multiple burners.
 17. The method as recited in claim 11 wherein said gas burner is a first gas burner and said method further comprising coupling second and third gas burners to said fuel/air controller.
 18. The method as recited in claim 11 wherein said gas burner, said fuel/air control valve, said blower, and said controller are a first gas burner, a first fuel/air control valve, a first blower, and a first controller, respectively; and said method further comprising: providing a second gas burner; coupling a second fuel/air control valve to said second gas burner; coupling a second blower to said second gas burner; and coupling a second controller to said second fuel/air control valve wherein said second controller controls at least one operation parameter of said second fuel/air control valve and said second blower to provide a second flame pattern generated by said second gas burner.
 19. The method as recited in claim 18 wherein said at least one operational parameter of said second fuel/air control valve and said second blower is selected from the group consisting of: a fuel velocity; an air velocity; a fuel/air ratio; and an equivalence ratio.
 20. The method as recited in claim 18 further comprising coupling said first and second control valves to multiple burners. 